Seamless foam panel roofing system

ABSTRACT

A crush resistant seamless roofing system is formed by a layer of adjacent panels having loose joints filled by expanding rising foam adhesive, which is trimmed to remove excess foam adhesive above a top plane of the roofing system. The roofing system thus formed is covered by a fabric layer and a coating.

FIELD OF THE INVENTION

[0001] The present invention relates to roofing systems.

BACKGROUND OF THE INVENTION

[0002] Rigid foam panels are currently available for use as aninsulating underlayment in roof construction. Typically these are 4′ by8′ (1.22 m by 2.44 m) panels 1.5″ (3.8 cm) thick made of a 1.6 pound percubic foot polyurethane foam with a tar paper top layer. Such a materialis not crush resistant enough to be used as a roof surface material andcan also be easily punctured.

OBJECTS OF THE INVENTION

[0003] It is therefore an object of the present invention to provide asturdy, weatherproof, seamless roofing system that uses rigid foamboards or panels to create a seamless waterproof roof.

SUMMARY OF THE INVENTION

[0004] The roofing panels of this invention differ from the prior artunderlayment product in several respects. The panels of this inventionare:

[0005] a) made of a denser polyurethane foam (approximately 3 pounds percubic foot) and,

[0006] b) include an integral top layer of non-woven 250 gram polyesterfabric that is saturated by the foam during manufacture by the laminatorin a controlled factory environment.

[0007] The higher density affords more crush resistance, while the wellbonded top layer resists punctures and provides a better adhesionsurface for elastomeric top coats.

[0008] The roofing panels are bonded to roof substrate with low risefoam polyurethane adhesive which seeps through loose tongue-in-groovejoints to form a blob at the top, which is shaved off and covered with afabric top layer.

[0009] After the adhesive cures, a very secure bond between the panelsresults.

[0010] The low rise foam adhesive is a two-part mixture that hasdistinct phases after mixing. By varying the formulations of the twoparts, the “cream time” (i.e.—to achieve the consistency of shavingcream) as well as the “tack free” time can be controlled.

[0011] The panels are placed on the foam just after cream consistencyand well before tack-free time so that the foam rises through thejoints. After the adhesive cures to a solid consistency, the blobs areremoved from all of the joints. This is typically accomplished bygrinding using a disk pad grinder.

[0012] The roof is finished by applying a layer of waterproofelastomeric coating which covers the entire surface creating amonolithic structure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention can best be understand in connection withthe accompanying drawings, in which:

[0014]FIG. 1 is a top plan view of a roof section; showing outlines ofroofing panels of this invention;

[0015]FIG. 2 is a top plan view of an embodiment for a tongue-in-grooveroofing panel of this ivention;

[0016]FIG. 3 is an edge crossection detail view of further embodimentfor an all-groove panel of this invention with an insertable tongueboard;

[0017]FIG. 4 is an edge crossection view of yet another embodiment fortongue-in-groove roofing panels of this invention, shown adhesivelybonded to a roof substrate;

[0018]FIG. 5 is an edge crossection detail view of a still furtheralternate embodiment of this invention, shown with a ship-lap jointconfiguration;

[0019]FIG. 6 is an edge crossection detail view showing a panel joint ofthis invention in a finished roof section;

[0020]FIG. 7 is a high level flow chart of the roofing system method ofthis invention; and,

[0021]FIG. 8 is a roof edge detail view in crossection, illustratingflashing and interfacing to the roofing system of this invention.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The roofing system of this invention uses rigid foam boards orpanels to create a seamless waterproof roof. It can be used over anumber of different substrates including metal decking, tar and gravel,or polyurethane foam in new construction as well as re-roofingapplications.

[0023] Rigid foam panels are currently available for use as insulatingunderlayment in roof construction. Typically these are 4′ by 8′ (1.22 mby 2.44 m) panels 1.5″ (3.8 cm) thick made of a 1.6 pound per cubic footpolyurethane foam with a tar paper top layer. Such a material is notcrush resistant enough to be used as a roof surface material and canalso be easily punctured.

[0024] The roofing panels of this invention differ from thisunderlayment product in several respects. Although panel size as well asmaterial are similar, the panels of this invention are made of a denserpolyurethane foam (approximately 3 pounds per cubic foot) and include anintegral top layer of non-woven 250 gram polyester fabric that issaturated by the foam during manufacture by the laminator in acontrolled factory environment. The higher density affords more crushresistance, while the well bonded top layer resists punctures andprovides a better adhesion surface for elastomeric top coats.

[0025]FIG. 1 is a top view of a roof 1 section showing the outline ofthe individual roof panels. The panel seams are staggered by usingalternate whole panels A as well as half panels B at the roof edge 2.This is done to prevent any tendency for propagation of inadvertent seamseparations.

[0026]FIG. 2 shows a top view of a tongue-in groove panel 5 tongue edges6 and groove edges 7.

[0027] Since a protruding tongue of polyurethane foam could be damagedin transit, an alternate embodiment of a tongue-in groove constructionis shown in FIG. 3. In this all-groove construction, each polyurethanepanel 10 has grooves 11 cut in all four edges. A length of polyurethaneplank 12 is then inserted in groove 11 on two edges at the work site.Plank 12 is dimensioned as a press fit in groove 11 and protrudes fromthe edge to form the tongue after insertion. Planks 12 would be shippedseparately in protective packaging to the work site.

[0028]FIG. 4 is an edge crossection view of roofing panels 5 bonded toroof substrate 16 with low rise foam polyurethane adhesive 17 whichseeps through loose tongue-in-groove joints to form a blob 18 at thetop. Factory bonded fabric 15 is a top layer. Typically, the groove 7 is⅞″ (22 mm) wide while the tongue is ¾″ (19 mm) wide; this affords enoughspace for the adhesive foam to rise through while affording closeline-up of the top surfaces of adjacent boards 5. After adhesive 17cures, a very secure bond between panels 5 results.

[0029]FIG. 5 is a detail of an alternative panel joint. Here panels 20have a ship-lap edge which is also dimensioned so as to permit risingfoam adhesive to flow through the joint. For ship-lap panels 20, theorder in which they are laid into the foam is important.

[0030] As shown in FIG. 5, panel X should be laid down before panel Y sothat there would not be a tendency to lift panel Y during the foamrising phase.

[0031] Foam adhesive is a two-part mixture that has distinct phasesafter mixing. By varying the formulations of the two parts, the “creamtime” (i.e.—to achieve the consistency of shaving cream) as well as the“tack free” time can be controlled. For this invention, a cream time ofabout 1 minute and a tack-free time of about 4 minutes is ideal. Thepanels are placed on the foam just after cream consistency and wellbefore tack-free time so that the foam rises through the joints.

[0032] After the adhesive cures to a solid consistency, the blobs 18 areremoved from all of the joints. This is typically accomplished bygrinding using a cutter, such as a knife or disk pad grinder. At thisstage, the joint is flush with the fabric top surface of the adjacentpanels.

[0033] The roof is finished by applying a layer of waterproofelastomeric coating which covers the entire surface creating amonolithic structure.

[0034]FIG. 6 is a detail of a finished joint between two panels 5 afterthe blob 18 has been removed and elastomeric coating 25 has beenapplied. Coating 25 can be an acrylic, urethane or silicone material. Itcan be sprayed or brushed on.

[0035] Flow chart 7 is a concise description of the overall installationprocess. Two people are generally involved as a team. One worker spraysa panel-width line of low rise polyurethane adhesive, while the secondworker follows (after the mix is of cream consistency) and lay downpanels. As per FIG. 1, the first panel at an edge is either a full orhalf panel to create the staggered seam pattern. Only after the entireroof (or large section) is paneled, are the seep-through joint blobsremoved. All debris must be removed carefully before a final seal coatis applied.

[0036] Penetrations and wall flashings are first sealed with spray foamprior to sealing.

[0037]FIG. 8 is a detail at a roof edge showing an end panel 5interfacing with aluminum edging 30 which bridges wall 31, beam 29 andfoam panel 5. A V-groove 28 is cut from the corner of panel 5 at thejuncture of edging 30 to permit an aluminum surface to be bonded andsealed to the fabric 15 top layer by waterproof coating 25.

[0038] It is further noted that other modifications may be made to thepresent invention, within the scope of the invention, as noted in theappended Claims.

I claim:
 1. A method of installing roofing tiles comprising: a) sprayinga foam rising adhesive on a surface; b) waiting for said foam risingadhesive to obtain a creamy consistency; c) applying a first tile paneland an adjacent first subsequent tile panel to said surface; d) waitingfor said adhesive to cure and rise within a joint formed between saidfirst tile panel and said first subsequent tile panel; e) applyingfurther tile panel and subsequent further tile panel to said surface; f)waiting for said adhesive to cure and rise within further joints formedbetween said first subsequent tile and said further tile panel; g)repeating steps “c”, “d” and “e” and “f” on next subsequent pairs oftile panels until said foam adhesive completes rising between saidjoints and accumulates as debris above a plane formed by said tilepanels accumulated in a seamless configuration; h) removing debrisformed by said foam rising adhesive from the top surface of said tilepanels; and, I) applying an elastomeric coat to the top surface of saidjoined, seamless accumulation of tile panels.
 2. A method of installingroofing tiles according to claim 1, wherein said elastomer is anacrylic.
 3. A method of installing roofing tiles according to claim 1,wherein said elastomer is a urethane.
 4. A method of installing roofingtiles according to claim 1, wherein said elastomer is silicone based. 5.A method of installing roofing tile panels according to claim 2, whereinapplication of said first and said subsequent tile panels furthercomprises: applying said first tile panel having a first length; andapplying said second tile panel having a second length, wherein saidsecond length of said second tile panel is different than said firstlength of said first tile panel.
 6. A hardened foam panel comprising: afirst sheet of polyurethane foam wherein said first sheet has a densityof about 2.5 to 3.16 cubic pounds per foot and said first sheet has atop surface, a bottom surface, and a first periphery; and said topsurface having an integral layer of non-woven polyester fabric.
 7. Afoam panel according to claim 6, wherein said first periphery isreceptive to a second sheet of polyurethane foam having a secondperiphery, said second sheet having a density substantially equal tosaid density of said first sheet, and said first and said secondperiphery allow an adhesive to rise therebetween.
 8. A foam panelaccording to claim 7, wherein said first and said second periphery aretongue and groove, respectively.
 9. A foam panel according to claim 8,wherein said groove is about 22 mm wide and said tongue is about 19 mmwide.
 10. A foam panel according to claim 7, wherein said first and saidsecond periphery is ship and lap, respectively.
 11. A foam panelaccording to claim 7, wherein said first periphery and said secondperiphery has a first and a second groove, respectively; and a tongueslideably mounted within said first and said second grooves.
 12. A crushresistant and puncture resistant seamless waterproof roofing systemcomprising a plurality of adjacent cured foam panels attached to aroofing by a foaming adhesive bonding said panels to a substrate of saidroof, said adhesive rising between said panels, sealing said panels toeach other by expansion through loose inter-panel joints between saidpanels, said panels having an on-site coat of elastomeric sealingmaterial thereon, said coat of elastomeric sealing material covering afabric layer above each of said panels.
 13. The roofing system as inclaim 12 wherein said panels are polyurethane.
 14. The roofing system asin claim 12 wherein said sealing material is a silicone.
 15. The roofingsystem as in claim 13 wherein said polyurethane is a dense polyurethanefoam having a strength of at least three pounds per cubic foot.
 16. Theroofing system as in claim 12 wherein said fabric is an integral toplayer of non-woven 250 gram polyester fabric saturated by said foam. 17.The roofing system as in claim 16 wherein adjacent panels havetongue-in-groove edges fitting into adjacent tongue and groove edged ofadjacent panels.
 18. The roofing system as in claim 17 wherein saidadhesive is low rise foam polyurethane adhesive, said adhesive seepingthrough loose tongue-in groove joints.
 19. The roofing system as inclaim 12 wherein said foaming adhesive used to both bond the said panelsto a substrate and to rise between said panels, seals said panels toeach other through loose inter-panel joints accommodating said risenadhesive therebetween, forming a seamless accumulation of said panels.20. The roofing system as in claim 12 wherein said roof has panel seamswhich are staggered by using alternate whole panels as well as halfpanels upon said roof.
 21. The roofing system as in claim 12 furthercomprising an elastomeric coating applied over said panels.
 22. Theroofing system as in claim 21 wherein an of said plurality of panelsincludes an edging bridging a wall under said roof, a support beamsupporting said panels, and said panels.